Disposable absorbent article with a skin care composition on an apertured top sheet

ABSTRACT

A disposable absorbent article, such as a diaper. The disposable absorbent article has a liquid pervious structured carrier, a liquid impervious backsheet at least partially peripherally joined to the structured carrier; and an absorbent core intermediate the structured carrier and the backsheet. The liquid pervious structured carrier has an inner surface oriented toward the interior of the disposable absorbent article and an outer surface oriented toward the skin of the wearer when the disposable absorbent article is worn The structured carrier has an effective open area of at least about 12 percent and a plurality of apertures with an effective size greater than 0.1 square millimeters. The outer surface of the structured carrier has an effective amount of a skin care composition which is semi-solid or solid at 20° C. and which is partially transferable to the wearer&#39;s skin.

FIELD OF THE INVENTION

This invention relates to disposable absorbent articles, such as diapersand adult incontinence products, and more particularly to disposableabsorbent articles which have the ability to effectively handle bothurine and low-viscosity fecal material.

BACKGROUND OF THE INVENTION

Many types of disposable absorbent products, such as diapers, areavailable that have a high capacity for absorbing urine. Disposableproducts of this type generally comprise some sort of fluid-permeabletopsheet material, an absorbent core, and a fluid-impermeable backsheetmaterial. Although these types of absorbent structures may be highlyefficient for the absorption of fluids, they cannot absorb bowelmovements ( i.e., hereinafter referred to as “BM”). Typically, the BM istrapped between the outer surface of the fluid-permeable topsheet andthe skin of the wearer, much of it adhering to the wearer's skin.

To prevent BM from adhering to the wearer's skin, the caregiver oftenapplies protective or “repellent” products such as vaseline or mineraloil to the buttocks and anal region before placing the absorbent articleon the wearer. This procedure usually involves the caregiver's pouringof the oil or lotion, for example, in one of their hands, rubbing bothhands together to distribute the substance thereon and then wiping thesame on the skin of the infant. To eliminate the need for this wasteful,messy, and easily forgotten procedure, there have been numerous previousattempts to prepare absorbent articles which contain a protective ortherapeutic skin care substance on the topsheet.

One substance that has been applied as a lotion to absorbent products toimpart a soothing, protective coating is mineral oil. Mineral oil (alsoknown as liquid petrolatum) is a mixture of various liquid hydrocarbonsobtained by distilling the high-boiling (i.e., 330°-390° C.) fractionsin petroleum. Mineral oil is liquid at ambient temperatures, e.g. 20°-25° C. As a result, mineral oil is relatively fluid and mobile, evenwhen applied to article topsheets.

Because mineral oil is fluid and mobile at ambient temperatures, ittends not to remain localized on the surface of the topsheet, butinstead migrates through the topsheet into the interior of the diaper.Accordingly, relatively high levels of mineral oil need to be applied tothe topsheet to provide the desired therapeutic or protective coatinglotion benefits. This leads not only to increased costs for theselotioned products, but other detrimental effects as well.

One of these detrimental effects is a decrease in the fluid handlingproperties as high levels of mineral oil tend to block the topsheetopenings. Also, as mineral oil migrates to the interior of the article,it tends to act as a hydrophobic additive, thus decreasing theabsorbency of the underlying absorbent core, if one is used. Thisdecrease in absorbency becomes more pronounced as the level of mineraloil applied is increased.

Even without increasing its level, the tendency of mineral oil tomigrate once applied has other detrimental effects. For example, theapplied mineral oil can transfer to, into and through the packaging orwrapper material for the lotioned product. This can create the need forbarrier-type packaging or wrapper films to avoid smearing or otherleakage of mineral oil from the product.

To overcome the problems associated with mineral oils, lotions have beenapplied to absorbent products. Lotioned absorbent products: (1) havetherapeutic or protective benefits, (2) do not require relatively highlevels of coatings that are liquid at room temperature (e.g., mineraloil); and (3) do not require special wrapping or barrier materials forpackaging.

While lotioned absorbent products do solve the problems associated withmineral oils, care has to be taken in application of the lotion to theabsorbent products to prevent occlusion of the topsheet. Such occlusionof the pervious topsheet prevents urine from penetrating through thetopsheet inevitably leading to leakage. In order to overcome thisproblem, lotion has been applied to topsheets in such a manner so as tonot coat the entire surface of the topsheet thereby leaving portions ofthe topsheet free of lotion. An example of such a coating technique isthe application of lotion in stripes spaced apart from one another.While stripes of lotion do permit urine to penetrate the topsheet thereis an added complexity in the application process, there is thepotential for non-uniform transfer of the lotion to the skin and thepotential for contamination of the untreated areas of the topsheetthereby reducing the transfer of urine to the underlying absorbentelement.

Therefore, it is an object of the present invention to provide adisposable absorbent article having a structured carrier having superiorurine and BM handling properties. As used herein, the term “structuredcarrier” refers to any two-dimensional or three-dimensionalmorphological arrangement designed to carry and then transfer acomposition while maintaining pathways such that urine may passtherethrough.

It is a further object of the present invention to provide a structuredcarrier for a disposable absorbent article having an effective open areaand a plurality of apertures having a sufficient effective size to allowurine and low-viscosity fecal material penetration therethrough suchthat a skin care composition can be applied with relative ease as theconcern for occlusion of the structured carrier has been removed. Asused herein, the term “skin care composition” refers to any compositionwhich comprises one or more agents which, when transferred from anarticle to a wearer's skin, provide a therapeutic and/or protective skinbenefit. Representative materials are discussed in detail below.

It is a further object of the present invention to provide an absorbentarticle having a skin care composition on the outer surface of thestructured carrier that is transferable to the wearer's skin and iseffective at producing desired skin benefits and/or reducing theadherence of BM to the skin, thereby improving the ease of BM cleanupwhile not inhibiting the structured carriers ability to handle urine.

These and other objects are obtained using the present invention, aswill become readily apparent from a reading of the following disclosure.

BRIEF SUMMARY OF THE INVENTION

The invention is a disposable absorbent article, such as a diaper. Thedisposable absorbent article comprises a structured carrier, a liquidimpervious backsheet at least partially peripherally joined to thestructured carrier, and an absorbent core intermediate the structuredcarrier and the backsheet. The structured carrier has an inner surfaceoriented toward the interior of the disposable absorbent article and anouter surface oriented toward the skin of the wearer when the disposableabsorbent article is worn. The structured carrier has an effective openarea of at least about 12 percent and a plurality of apertures with aneffective size greater than 0.1 square millimeters. The outer surface ofthe structured carrier comprises an effective amount of a skin carecomposition which is semi-solid or solid at 20° C. and which ispartially transferable to the wearer's skin.

BRIEF DESCRIPTION OF THE DRAWINGS

While the Specification concludes with claims pointing out anddistinctly claiming the present invention, it is believed the same willbe better understood by the following drawings taken in conjunction withthe accompanying Specification wherein like components are given thesame reference number and:

FIG. 1 is a top plan view, shown partially in cutaway, of a disposableabsorbent article according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

As used herein, the term “absorbent article” refers to devices whichabsorb and contain body exudates, and, more specifically, refers todevices which are placed against or in proximity to the body of thewearer to absorb and contain the various exudates discharged from thebody. The term “disposable” is used herein to describe absorbentarticles which are not intended to be laundered or otherwise restored orreused as an absorbent article (i.e., they are intended to be discardedafter a single use and, preferably, to be recycled, composted orotherwise disposed of in an environmentally compatible manner). A“unitary” absorbent article refers to absorbent articles which areformed of separate parts united together to form a coordinated entity sothat they do not require separate manipulative parts like a separateholder and liner. A preferred embodiment of an absorbent article of thepresent invention is the unitary disposable absorbent article, diaper20, shown in FIG. 1. As used herein, the term “diaper” refers to anabsorbent article generally worn by infants and adult incontinentpersons and is worn about the lower torso of the wearer. The presentinvention is also applicable to other absorbent articles such asincontinence briefs, incontinence undergarments, absorbent inserts,diapers holders and liners, feminine hygiene garments, and the like.

FIG. 1 is a plan view of the diaper 20 of the present invention in itsflat-out, uncontracted state (i.e., with elastic induced contractionpulled out) with portions of the structure being cut-away to moreclearly show the construction of the diaper 20 and with the portion ofthe diaper 20 which faces or contacts the wearer, the inner surface,oriented towards the viewer. As shown in FIG. 1, the diaper 20preferably comprises a liquid pervious structured carrier 24; a liquidimpervious backsheet 26 joined with the structured carrier 24; and anabsorbent core 28 intermediate the structured carrier 24 and thebacksheet 26. The diaper 20 may further comprise elasticized side panels(not shown); elasticized leg cuffs (not shown); an elastic waist feature(not shown); and a fastening system with tape tabs generally multiplydesignated as 36.

The diaper 20 is shown in FIG. 1 to have a first waist region 27juxtaposed with the front of the wearer while the diaper 20 is beingworn, a second waist region 29 opposed to the first waist region 27 andjuxtaposed with the back of the wearer while the diaper 20 is beingworn, a crotch region 31 positioned between the first waist region 27and the second waist region 29, and a periphery which is defined by theouter edges of the diaper 20 in which the longitudinal edges aredesignated 33 and the end edges are designated 35. The inner surface ofthe diaper 20 comprises that portion of the diaper 20 which is adjacentto the wearer's body during use (i.e., the inner surface generally isformed by at least a portion of the structured carrier 24 and othercomponents joined to the structured carrier 24). The outer surfacecomprises that portion of the diaper 20 which is positioned away fromthe wearer's body (i.e., the outer surface generally is formed by atleast a portion of the backsheet 26 and other components joined to thebacksheet 26) during use.

FIG. 1 shows an embodiment of the diaper 20 in which the structuredcarrier 24 and the backsheet 26 have length and width dimensionsgenerally larger than those of the absorbent core 28. The structuredcarrier 24 and the backsheet 26 extend beyond the edges of the absorbentcore 28 to thereby form the periphery of the diaper 20. While thestructured carrier 24, the backsheet 26, and the core 28 may beassembled in a variety of well known configurations, preferred diaperconfigurations are described generally in U.S. Pat. No. 3,860,003entitled “Contractable Side Portions for Disposable Diaper” which issuedto Kenneth B. Buell on Jan. 14, 1975; and U.S. Pat. No. 5,151,092,“Absorbent Article With Dynamic Elastic Waist Feature Having APredisposed Resilient Flexural Hinge”, issued to Kenneth B. Buell et al.Sep. 29, 1992; each of which is incorporated herein by reference.

The absorbent core 28 may be any absorbent means which is generallycompressible, conformable, non-irritating to the wearer's skin, andcapable of absorbing and retaining liquids such as urine and othercertain body exudates. As shown in FIG. 1, the absorbent core 28 has agarment surface, a body surface, side edges, and waist edges. Theabsorbent core 28 may be manufactured in a wide variety of sizes andshapes (e.g., rectangular, hourglass, “T”-shaped, asymmetric, etc.) andfrom a wide variety of liquid-absorbent materials commonly used indisposable diapers and other absorbent articles such as comminuted woodpulp which is generally referred to as airfelt. Examples of othersuitable absorbent materials include creped cellulose wadding; meltblownpolymers including coform; chemically stiffened, modified orcross-linked cellulosic fibers; tissue including tissue wraps and tissuelaminates; absorbent foams; absorbent sponges; superabsorbent polymers;absorbent gelling materials; or any equivalent material or combinationsof materials.

The configuration and construction of the absorbent core 28 may also bevaried (e.g., the absorbent core 28 may have varying caliper zones, ahydrophilic gradient, a superabsorbent gradient, or lower averagedensity and lower average basis weight acquisition zones; or maycomprise one or more layers or structures). The total absorbent capacityof the absorbent core 28 should, however, be compatible with the designloading and the intended use of the diaper 20. Further, the size andabsorbent capacity of the absorbent core 28 may be varied to accommodatewearers ranging from infants through adults.

Exemplary absorbent structures for use as the absorbent core 28 aredescribed in U.S. Pat. No. 4,610,678 entitled “High-Density AbsorbentStructures” issued to Weisman et al. on Sep. 9, 1986; U.S. Pat. No.4,673,402 entitled “Absorbent Articles With Dual-Layered Cores” issuedto Weisman et al. on Jun. 16, 1987; U.S. Pat. No. 4,888,231 entitled“Absorbent Core Having A Dusting Layer” issued to Angstadt on Dec. 19,1989; and U.S. Pat. No. 4,834,735, entitled “High Density AbsorbentMembers Having Lower Density and Lower Basis Weight Acquisition Zones”,issued to Alemany et al. on May 30, 1989. Each of these patents isincorporated herein by reference.

The backsheet 26 is positioned adjacent the garment surface of theabsorbent core 28 and is preferably joined thereto by attachment means(not shown) such as those well known in the art. As used herein, theterm “joined” encompasses configurations whereby an element is directlysecured to the other element by affixing the element directly to theother element, and configurations whereby the element is indirectlysecured to the other element by affixing the element to intermediatemember(s) which in turn are affixed to the other element.

For example, the backsheet 26 may be secured to the absorbent core 28 bya uniform continuous layer of adhesive, a patterned layer of adhesive,or an array of separate lines, spirals, or spots of adhesive. Adhesiveswhich have been found to be satisfactory are manufactured by H. B.Fuller Company of St. Paul, Minn. and marketed as HL-1258. Theattachment means will preferably comprise an open pattern network offilaments of adhesive as is disclosed in U.S. Pat. No. 4,573,986entitled “Disposable Waste-Containment Garment”, which issued toMinetola et al. on Mar. 4, 1986, more preferably several lines ofadhesive filaments swirled into a spiral pattern such as is illustratedby the apparatus and methods shown in U.S. Pat. No. 3,911,173 issued toSprague, Jr. on Oct. 7, 1975; U.S. Pat. No. 4,785,996 issued to Ziecker,et al. on Nov. 22, 1978; and U.S. Pat. No. 4,842,666 issued to Wereniczon Jun. 27, 1989. Each of these patents is incorporated herein byreference. Alternatively, the attachment means may comprise heat bonds,pressure bonds, ultrasonic bonds, dynamic mechanical bonds, or any othersuitable attachment means or combinations of these attachment means asare known in the art.

The backsheet 26 is impervious to liquids (e.g., urine) and ispreferably manufactured from a thin plastic film, although otherflexible liquid impervious materials may also be used. As used herein,the term “flexible” refers to materials which are compliant and willreadily conform to the general shape and contours of the human body.

The backsheet 26 prevents the exudates absorbed and contained in theabsorbent core 28 from wetting articles which contact the diaper 20 suchas bedsheets and undergarments. The backsheet 26 may thus comprise awoven or nonwoven material, polymeric films such as thermoplastic filmsof polyethylene or polypropylene, or composite materials such as afilm-coated nonwoven material. Preferably, the backsheet 26 is athermoplastic film having a thickness of about 0.012 mm (0.5 mil) toabout 0.051 mm (2.0 mils). Particularly preferred materials for thebacksheet 26 include RR8220 blown films and RR5475 cast films asmanufactured by Tredegar Industries, Inc. of Terre Haute, Ind. Thebacksheet 26 is preferably embossed and/or matte finished to provide amore clothlike appearance. Further, the backsheet 26 may permit vaporsto escape from the absorbent core 28 (i.e., be breathable) while stillpreventing exudates from passing through the backsheet 26.

The structured carrier 24 has a first or inner surface oriented towardthe interior of the disposable diaper, specifically oriented toward theabsorbent core 28, and an opposed second or outer surface orientedtoward the skin of the wearer when the diaper is worn.

The structured carrier 24 is juxtaposed with, but not necessarilyadjacent the body surface of the absorbent core 28, and is preferablyjoined to the backsheet 26 or absorbent core 28 by means such as thosewell known in the art. Suitable attachment means are described abovewith respect to joining the backsheet 26 to the absorbent core 28. In apreferred embodiment of the present invention, the structured carrier 24and the backsheet 26 are joined directly to each other in the diaperperiphery.

The structured carrier 24 is compliant, soft feeling, and non-irritatingto the wearer's skin. Further, the structured carrier 24 is liquidpervious, permitting liquids (e.g., urine) to readily penetrate throughits thickness. A suitable structured carrier 24 may be manufactured froma wide range of materials, such as porous foams; reticulated foams;apertured plastic films; or woven or nonwoven webs of natural fibers(e.g., wood or cotton fibers), synthetic fibers (e.g., polyester orpolypropylene fibers), or a combination of natural and synthetic fibers.Preferably, the structured carrier 24 is made of a hydrophobic materialto isolate the wearer's skin from liquids contained in the absorbentcore 28. Alternatively, the structured carrier 24 may be surfactanttreated to make it hydrophilic.

The structured carrier 24 preferably has a plurality of apertures withan effective aperture size of at least 0.2 square millimeters, morepreferably, the plurality of apertures have an effective aperture sizeof at least 0.5 square millimeters, even more preferably, the pluralityof apertures have an effective aperture size of at least 1.0 squaremillimeters, and most preferably, the plurality of apertures have aneffective aperture size of at least 2.0 square millimeters. Effectiveapertures are those which have a gray level of 18 or less on a standardgray level scale of 0-255, under the image acquisition parametersdescribed below.

The structured carrier 24 preferably has an effective open area of atleast 15 percent, more preferably the structured carrier has aneffective open area of at least 20 percent, even more preferably, thestructured carrier has an effective open area of at least 25 percent,and most preferably the structured carrier has an effective open area ofat least 30 percent.

The effective aperture size and effective open area are determined bythe following procedure using the image analysis described below. Theprocedure has three principal steps: image acquisition, i.e., obtainingrepresentative images of areas on the surface of the structured carrier24; image measurement, i.e., measuring the percentage open area of animage and of individual apertures and their perimeters; and dataanalysis, i.e., exporting the percentage open area, individual aperturearea, and perimeter measurements to a spreadsheet where frequencydistributions, sum of area distributions, and hydraulic radiuscomputations are made.

An image analysis system having a frame grabber board, microscope,camera and image analysis software is utilized. A model DT2855 framegrabber board available from Data Translation of Marlboro, Mass. isprovided. A VH5900 monitor microscope, a video camera, having aVH50 lenswith a contact type illumination head available from the Keyence Companyof Fair Lawn, N.J. are also provided and used to acquire an image to besaved to computer file. The Keyence microscope acquires the image andthe frame grabber board converts the analog signal of this image intocomputer readable digital format. The image is saved to computer fileand measured using suitable software such as the Optimas Image Analysissoftware, version 3.1, available from the BioScan Company of Edmaons,Wash. In order to use the Optimas Image Analysis software, the computershould have Windows software, version 3.0 or later, available from theMicrosoft Corporation of Redmond, Wash. And also have a CPU at leastequivalent to the Intel 80386. Any suitable desk top PC may be used,with a 486 DX33 type PC having been found to be particularly suitable.Images being saved to and recalled from file were displayed on a SonyTrinitron monitor model PVM-1343MO with a final display magnification ofabout 50×.

The image acquisition step, noted above requires 10 different regionsfrom a representative structured carrier 24 sample of a particular typeof diaper 20 or from sample material to be tested. Each region isrectangular, measuring about 5.8 millimeters by 4.2 millimeters. Thesample is placed on a black mat board to increase the contrast betweenthe apertures and the portion of the sample which defines the apertures.The mean gray level and standard deviation of the black mat board were16 and 4, respectively.

Images are acquired with room lights off using the Keyence monitormicroscope mounted on a copystand directly above the sample. The Keyencelight source illuminating the sample is adjusted and monitored with theOptimas software to measure the mean gray level and standard deviationof a 0.3 density wedge on a Kodak Gray Scale available from EastmanKodak Company of Rochester, N.Y. The control of Keyence light source isadjusted so that the mean gray level of the illuminated wedge is 111±1and the standard deviation is 10±1. All images were acquired during asingle time period, and the Keyence light source is monitored bymeasuring the mean gray level and standard deviation of the wedgethroughout the image acquisition process.

In measuring an individual aperture, only the effective aperture size isof interest. Measuring the effective aperture size quantifies theaperture size intended to contribute to the porosity of the structuredcarrier 24, and account for contributions of fibers and fiber bundleswhich traverse an area intended to be an aperture. An effective apertureis any hole through the structured carrier 24 having a gray level lessthan or equal to 18 using image acquisition parameters as describedherein. Thus, an intended aperture may be divided into plural effectiveapertures by traverse fibers.

The image analysis software is calibrated in millimeters by a rulerimage acquired from the sample images. A 3 by 3 pixel averaging filterfound in the Optimas 3.1 Image menu is applied to each saved image toreduce noise. The apertures are detected in the gray level range of 0through 18. An aperture which is not fully contained within the 5.8 by4.2 viewing area is not considered in the individual area and perimetermeasurements. Therefore, area and perimeter averages and distributionsare not affected by apertures which are not wholly contained within thefield of view.

However, individual apertures which could not be fully viewed in theimage are included in the percentage open area calculation. Thisdifference occurs because the percent open area is simply the image ofpixel ratios from 0 through 18 to the total number of pixels in theimage. Areas having a gray level 19 or greater were not counted in theopen area calculation.

The percentage open area for the average of 10 images for eachstructured carrier 24 is measured using the Optimas Image Analysissoftware. The percentage open area is defined as the ratio of the numberof pixels having a gray level from 0 through 18 to the total number ofpixels for the image. The percentage open area is measured for eachimage representing one particular region from a structured carriersample. The percentage open area from each of the 10 individual imagesis then averaged to yield a percentage open area for the entire sample.

The data analysis is conducted by an Excel spreadsheet, also availablefrom the Microsoft Corporation of Redmond, Wash. The Excel spreadsheetorganized the percentage open area, aperture area, and apertureperimeter measurements obtained from the Optimas software. Sampleaverages and standard deviations, size and frequency distributions ofindividual aperture areas and hydraulic radius computations (areadivided by perimeter) for individual apertures are obtained using thespreadsheet.

Distributions of individual aperture area are also computed using theExcel spreadsheet. The apertures are sorted into bins of certain sizeranges. The number of aperture areas falling into certain size ranges ofinterest is determined as well as the sum of the areas within eachrange. The ranges are set in increments of 0.05 square millimeters.These areas are expressed as a percentage of the total open area of thesample. The frequency and sum of the area distributions are obtained bycombining individual aperture measurements from all 10 images for eachsample.

There are a number of manufacturing techniques which may be used tomanufacture the structured carrier 24. For example, the structuredcarrier 24 may be a nonwoven web of fibers spunbonded, carded, wet-laid,meltblown, hydroentangled, combinations or composite laminates of theabove, or the like. Preferred structured carriers 24 include acarded/carded composite, hydroentangled over a wire forming screen andthermally air-through bonded by means well known to those skilled in thenonwovens art and hydroentanglement of fibrous webs. Alternatively,apertured formed films, woven netting, and woven apertured netting maybe suitable.

While the specific composition(s) delivered (referred to herein as “skincare composition” and “composition”) in accordance with the presentmethod is not the critical factor in achieving improved skin conditionof the area under the absorbent article, it is apparent that thecomposition must provide either a protective, nonocclusive function(e.g., a relatively liquid impervious but vapor pervious barrier) toavoid skin hyperhydration and skin exposure to materials contained inbody exudates, or it must contain agents that deliver, either directlyor indirectly, skin care benefits. For example, indirect benefitsinclude improved removal of skin irritants such as feces or urine. Thecomposition may be in a variety of forms, including, but not limited to,emulsions, lotions, creams, ointments, salves, powders, suspensions,encapsulations, gels, and the like.

As used herein, the term “effective amount of a skin care composition”refers to an amount of a particular composition which, when applied ormigrated to one or more of the wearer-contacting surface(s) of anabsorbent article(s), will be effective in providing a protectivebarrier and/or delivering a skin care benefit when delivered viaabsorbent articles over time. Of course, the effective amount ofcomposition applied to the article will depend, to a large extent, onthe particular composition used. Nonetheless, the quantity of thecomposition on at least a portion of the wearer-contacting surface ofthe absorbent article will preferably range from about 0.05 mg/in²(0.0078 mg/cm²) to about 80 mg/in² (12.4 mg/cm²), more preferably fromabout 1 mg/in² (0.16 mg/cm²) to about 40 mg/in² (6.20 mg/cm²), stillmore preferably from about 4 mg/in² (0.62 mg/cm²) to about 26 mg/in²(4.03 mg/cm²). These ranges are by way of illustration only and theskilled artisan will recognize that the nature of the composition willdictate the level that must be applied to achieve the desired skinbenefits, and that such levels are ascertainable by routineexperimentation in light of the present disclosure.

While the level of skin care composition applied to the absorbentarticle is an important aspect of the present methods, more important isthe amount of composition transferred to the wearer's skin during use ofone or more treated articles. Though the requisite level delivered tothe skin to provide the desired skin benefits will depend to some degreeon the nature of the composition employed, Applicants have found thatrelatively low levels may be delivered while still providing the desiredskin effects. This is particularly true for preferred compositions.

Another benefit of the present method is the controlled application ofthe skin care composition to deliver the low but effective levels ofcomposition required. This is in contrast to typically sporadic manualapplication of skin care agents, where the caregiver/user often appliessignificantly greater levels of material than are needed. Excessivematerials added manually may adversely impact the fluid handlingproperties of the absorbent article, as a result of transfer from theskin to the article. Indeed, for certain materials, such as petrolatum,the levels applied manually may actually result in an occlusive effect,thereby compromising the skin. A benefit of the present methods isproviding a barrier to surface moisture while avoiding occlusion of theskin (i.e., maintaining skin breathability). Thus, the present methods,which allow controlled composition delivery throughout the wear period,allow transfer of optimal levels of the composition to the skin toimprove skin condition.

With regard to the level of skin care composition that is transferred tothe wearer during use of one treated absorbent article worn for a periodof about 3 hours (a typical daytime wear time), preferred is where atleast about 0.01 mg/in² (0.0016 mg/cm²), more preferably at least about0.05 mg/in² (0.0078 mg/cm²), still more preferably at least about 0.1mg/in² (0.016 mg/cm²), of the composition is transferred to the skinover a three hour wear period. Typically, the amount of compositiondelivered by one treated article will be from about 0.01 mg/in² (0.0016mg/cm²) to about 5 mg/in² (0.78 mg/cm²), more preferably from about 0.05mg/in² (0.0078 mg/cm²) to about 3 mg/in² (0.47 mg/cm²), still morepreferably from about 0.1 mg/in² (0.016 mg/cm²) to about 2 mg/in² (0.31mg/cm²), over a three hour wear period.

For continual use of treated articles (in other words, changes occur inaccordance with normal use patterns, which typically include changesevery 3 to 4 hours during the day and a fresh article before overnightsleep) such as for a period of 24 hours, it will be preferred that atleast about 0.03 mg/in² (0.0047 mg/cm²), more preferably at least about0.1 mg/in² (0.016 mg/cm²), still more preferably at least about 0.3mg/in² (0.047 mg/cm²), of the composition is transferred to the wearer'sskin over the 24 hour period. Typically, the amount of compositiondelivered after a period of 24 hours where treated articles are appliedat each change, will be from about 0.03 mg/in² (0.0047 mg/cm²) to about18 mg/in² (2.79 mg/cm²), more typically from about 0.1 mg/in²(0.016mg/cm²) to about 10 mg/in² (1.55 mg/cm²), still more typically fromabout 0.3 mg/in² (0.047 mg/cm²) to about 6 mg/in² (0.93 mg/cm²).

It will be recognized that of the numerous materials useful in the skincare compositions delivered to skin in accordance with the presentmethods, those that have been deemed safe and effective skin care agentsare logical materials for use herein. Such materials include Category Iactives as defined by the U.S. Federal Food and Drug Administration's(FDA) Tentative Final Monograph on Skin Protectant Drug Products forOver-the-Counter Human Use, which presently include: alantoin, aluminumhydroxide gel, calamine, cocoa butter, dimethicone, cod liver oil (incombination), glycerine, kaolin, petrolatum, lanolin, mineral oil, sharkliver oil, white petrolatum, talc, topical starch, zinc acetate, zinccarbonate, zinc oxide, and the like. Other potentially useful materialsare Category III actives as defined by the U.S. Federal Food and DrugAdministration's Tentative Final Monograph on Skin Protectant DrugProducts for Over-the-Counter Human Use tentative final monograph onskin protectant drug products for over-the-counter human use, whichpresently include: live yeast cell derivatives, aldioxa, aluminumacetate, microporous cellulose, cholecalciferol, colloidal oatmeal,cysteine hydrochloride, dexpanthanol, Peruvian balsam oil, proteinhydrolysates, racemethionine, sodium bicarbonate, Vitamin A, and thelike.

Many of the FDA monographed skin care ingredients are currently utilizedin commercially available skin care products, such as A and D® Ointment,Vaseline® Petroleum Jelly, Desitin® Diaper Rash Ointment and Daily CareOintment, Gold Bond® Medicated Baby Powder, Aquaphor® Healing Ointment,Baby Magic® Baby Lotion, Johnson's Ultra Sensitive® Baby Cream,Johnson's baby lotion, lip balms, etc. These commercial products may beapplied to absorbent articles to create treated articles for use in thepresent methods, either with or without modification of the product tofacilitate delivery via this novel method.

As will be discussed hereinafter, the skin care compositions useful inthe methods of the present invention preferably, though not necessarily,have a melting profile such that they are relatively immobile andlocalized on the wearer-contacting surface of the article at roomtemperature, are readily transferable to the wearer at body temperature,and yet are not completely liquid under extreme storage conditions.Preferably, the compositions are easily transferable to the skin by wayof normal contact, wearer motion, and/or body heat. Because thecomposition preferably is substantially immobilized on the article'swearer-contacting surface, relatively low levels of composition areneeded to impart the desired skin care benefits. In addition, specialbarrier or wrapping materials may be unnecessary in packaging thetreated articles useful in the methods of the present invention.

In a preferred embodiment, the skin care compositions useful herein aresolid, or more often semi-solid, at 20° C., i.e. at ambienttemperatures. By “semisolid” is meant that the composition has arheology typical of pseudoplastic or plastic liquids. When no shear isapplied, the compositions can have the appearance of a semi-solid butcan be made to flow as the shear rate is increased. This is due to thefact that, while the composition contains primarily solid components, italso includes some minor liquid components. Preferably, the compositionsof the present invention have a zero shear viscosity between about1.0×10⁶ centipoise and about 1.0×10⁸. More preferably, the zero shearviscosity is between about 5.0×10⁶ centipoise and about 5.0×10⁷centipoise. As used herein the term “zero shear viscosity” refers to aviscosity measured at very low shear rates (e.g., 1.0 sec⁻¹) using plateand cone viscometer (a suitable instrument is available from TAInstruments of New Castle, DE as model number CSL 100). One of skill inthe art will recognize means other than high melting point components(as discussed below) can be used to provide comparable viscositiesmeasured for such compositions comprising such means can be measured byextrapolating a plot of viscosity vs. shear rate for such compositionsto a shear rate of zero at a temperature of about 20° C.

Preferred compositions are at least semi-solid at room temperature tominimize composition migration. In addition, the compositions preferablyhave a final melting point (100% liquid) above potential “stressful”storage conditions that can be greater than 45° C. (e.g., warehouse inArizona, car trunk in Florida, etc.). Representative compositions havingthese melt characteristics are described in detail in U.S. Pat. No.5,643,588 (Roe et al.), U.S. Pat. No. 5,607,760 (Roe et al.), U.S. Pat.Nos. 5,609,587, and 5,635,191, the disclosure of each of which isincorporated herein by reference. Specifically, preferred compositionswill have the following melt profile:

Characteristic Preferred Range Most Preferred % liquid at room temp.(20° C.)  2-50  3-25 % liquid at body temp. (37° C.) 25-95 30-90 finalmelting point (° C.) ≧38 ≧45

By being solid or semisolid at ambient temperatures, preferredcompositions do not have a tendency to flow and migrate to a significantdegree to undesired locations of the article to which they are applied.This means less skin care composition is required for impartingdesirable therapeutic, protective or conditioning benefits.

To enhance immobility of preferred compositions, the viscosity of theformulated compositions should be as high as possible to prevent flowwithin the article to undesired location. Unfortunately, in someinstances, higher viscosities may inhibit transfer of composition to thewearer's skin. Therefore, a balance should be achieved so theviscosities are high enough to keep the compositions localized on thesurface of the article, but not so high as to impede transfer to thewearer's skin. Suitable viscosities for the compositions will typicallyrange from about 5 to about 500 centipoise, preferably from about 5 toabout 300 centipoise, more preferably from about 5 to about 100centipoise, measured at 60_C using a rotational viscometer (a suitableviscometer is available from Lab Line Instruments, Inc. of Melrose Park,Ill. as Model 4537). The viscometer is operated at 60 rpm using a number2 spindle.

For compositions designed to provide a skin smoothness benefit, a usefulactive ingredient in these compositions is one or more skin protectantsor emollients. As used herein, the term “emollient” is a material thatprotects against wetness or irritation, softens, soothes, supples,coats, lubricates, moisturizes, protects and/or cleanses the skin. (Itwill be recognized that several of the monographed actives listed aboveare “emollients”, as that term is used herein.) In a preferredembodiment, these emollients will have either a plastic or liquidconsistency at ambient temperatures, i.e., 20° C. This particularemollient consistency allows the composition to impart a soft,lubricious, lotion-like feel.

Representative emollients useful in the present invention include, butare not limited to, emollients that are petroleum-based; polyolpolyesters; sucrose ester fatty acids; polyethylene glycol andderivatives thereof; humectants; fatty acid ester type; alkyl ethoxylatetype; fatty acid ester ethoxylates; fatty alcohol type; polysiloxanetype; propylene glycol and derivatives thereof; glycerine andderivatives thereof, including glyceride, acetoglycerides, andethoxylated glycerides of C₁₂-C₂₈ fatty acids; triethylene glycol andderivatives thereof; spermaceti or other waxes; fatty acids; fattyalcohol ethers, particularly those having from 12 to 28 carbon atoms intheir fatty chain, such as stearic acid; propoxylated fatty alcohols;other fatty esters of polyhydroxy alcohols; lanolin and its derivatives;kaolin and its derivatives; any of the monographed skin care agentslisted above; or mixtures of these emollients. Suitable petroleum-basedemollients include those hydrocarbons, or mixtures of hydrocarbons,having chain lengths of from 16 to 32 carbon atoms. Petroleum basedhydrocarbons having these chain lengths include mineral oil (also knownas “liquid petrolatum”) and petrolatun (also known as “mineral wax,”“petroleum jelly” and “mineral jelly”). Mineral oil usually refers toless viscous mixtures of hydrocarbons having from 16 to 20 carbon atoms.Petrolatum usually refers to more viscous mixtures of hydrocarbonshaving from 16 to 32 carbon atoms. Petrolatum and mineral oil areparticularly preferred emollients for compositions of the presentinvention.

Suitable fatty acid ester type emollients include those derived from C₁₂-C₂₈ fatty acids, preferably C₁₆-C₂₂ saturated fatty acids, and shortchain (C₁-C₈, preferably C₁-C₃) monohydric alcohols. Representativeexamples of such esters include methyl palmitate, methyl stearate,isopropyl laurate, isopropyl myristate, isopropyl palmitate, ethylhexylpalmitate and mixtures thereof. Suitable fatty acid ester emollients canalso be derived from esters of longer chain fatty alcohols (C₁₂-C₂₈,preferably C₁₂-C₁₆) and shorter chain fatty acids e.g., lactic acid,such as lauryl lactate and cetyl lactate.

Suitable alkyl ethoxylate type emollients include C₁₂-C₂₂ fatty alcoholethoxylates having an average degree of ethoxylation of from about 2 toabout 30. Preferably, the fatty alcohol ethoxylate emollient is selectedfrom the group consisting of lauryl, cetyl, and stearyl ethoxylates, andmixtures thereof, having an average degree of ethoxylation ranging fromabout 2 to about 23. Representative examples of such alkyl ethoxylatesinclude laureth-3 (a lauryl ethoxylate having an average degree ofethoxylation of 3), laureth-23 (a lauryl ethoxylate having an averagedegree of ethoxylation of 23), ceteth-10 (a cetyl alcohol ethoxylatehaving an average degree of ethoxylation of 10) and steareth-10 (astearyl alcohol ethoxylate having an average degree of ethoxylation of10). When employed, these alkyl ethoxylate emollients are typically usedin combination with the petroleum-based emollients, such as petrolatum,at a weight ratio of alkyl ethoxylate emollient to petroleum-basedemollient of from about 1:1 to about 1:5, preferably from about 1:2 toabout 1:4.

Suitable fatty alcohol type emollients include C₁₂-C₂₂ fatty alcohols,preferably C₁₆-C₁₈ fatty alcohols. Representative examples include cetylalcohol and stearyl alcohol, and mixtures thereof. When employed, thesefatty alcohol emollients are typically used in combination with thepetroleum-based emollients, such as petrolatum, at a weight ratio offatty alcohol emollient to petroleum-based emollient of from about 1:1to about 1:5, preferably from about 1:1 to about 1:2.

Other suitable types of emollients for use herein include polysiloxanecompounds. In general, suitable polysiloxane materials for use in thepresent invention include those having monomeric siloxane units of thefollowing structure:

wherein, R¹ and R², for each independent siloxane monomeric unit caneach independently be hydrogen or any allkyl, aryl, alkenyl, alkaryl,arakyl, cycloalkyl, halogenated hydrocarbon, or other radical. Any ofsuch radicals can be substituted or unsubstituted. R¹ and R² radicals ofany particular monomeric unit may differ from the correspondingfunctionalities of the next adjoining monomeric unit. Additionally, thepolysiloxane can be either a straight chain, a branched chain or have acyclic structure. The radicals R¹ and R² can additionally independentlybe other silaceous functionalities such as, but not limited tosiloxanes, polysiloxanes, silanes, and polysilanes. The radicals R¹ andR² may contain any of a variety of organic functionalities including,for example, alcohol, carboxylic acid, phenyl, and aminefunctionalities.

Exemplary alkyl radicals are methyl, ethyl, propyl, butyl, pentyl,hexyl, octyl, ecyl, octadecyl, and the like. Exemplary alkenyl radicalsare vinyl, allyl, and the like. xemplary aryl radicals are phenyl,diphenyl, naphthyl, and the like. Exemplary alkaryl adicals are toyl,xylyl, ethylphenyl, and the like. Exemplary aralkyl radicals are benzyl,alpha-phenylethyl, beta-phenylethyl, alpha-phenylbutyl, and the like.Exemplary cycloalkyl radicals are cyclobutyl, cyclopentyl, cyclohexyl,and the like. Exemplary halogenated hydrocarbon radicals arechloromethyl, bromoethyl, tetrafluorethyl, fluorethyl, trifluorethyl,trifluorotloyl, hexafluoroxylyl, and the like.

Viscosity of polysiloxanes useful may vary as widely as the viscosity ofpolysiloxanes in general vary, so long as the polysiloxane is flowableor can be made to be flowable for application to the article. Thisincludes, but is not limited to, viscosity as low as 5 centistokes (at37_C as measured by a glass viscometer) to about 20,000,000 centistokes.Preferably the polysiloxanes have a viscosity at 37° C. ranging fromabout 5 to about 5,000 centistokes, more preferably from about 5 toabout 2,000 centistokes, most preferably from about 100 to about 1000centistokes. High viscosity polysiloxanes which themselves are resistantto flowing can be effectively deposited upon the article by such methodsas, for example, emulsifing the polysiloxane in surfactant or providingthe polysiloxane in solution with the aid of a solvent, such as hexane,listed for exemplary purposes only. Particular methods for applyingpolysiloxane emollients to absorbent articles are discussed in moredetail hereinafter.

Preferred polysiloxanes compounds for use in the present invention aredisclosed in U.S. Pat. No. 5,059,282 (Ampulski et al), issued Oct. 22,1991, which is incorporated herein by reference. Particularly preferredpolysiloxane compounds for use as emollients in the compositions of thepresent invention include phenyl-functional polymethylsiloxane compounds(e.g., Dow Corning 556 Cosmetic-Grade Fluid: polyphenylmethylsiloxane)and cetyl or stearyl functionalized dimethicones such as Dow 2502 andDow 2503 polysiloxane liquids, respectively. In addition to suchsubstitution with phenyl-functional or alkyl groups, effectivesubstitution may be made with amino, carboxyl, hydroxyl, ether,polyether, aldehyde, ketone, amide, ester, and thiol groups. Of theseeffective substituent groups, the family of groups comprising phenyl,amino, alkyl, carboxyl, and hydroxyl groups are more preferred than theothers; and phenyl-functional groups are most preferred.

Suitable humectants include glycerine, propylene glycol, sorbitol,trihydroxy stearin, and the like.

When present, the amount of emollient that can be included in thecomposition will depend on a variety of factors, including theparticular emollient involved, the lotion-like benefits desired, theother components in the composition and like factors. The compositionwill comprise from 0 to about 100%, by total weight, of the emollient.Preferably, the composition will comprise from about 10 to about 95%,more preferably from about 20 to about 80%, and most preferably fromabout 40 to about 75%, by weight, of the emollient.

Another optional, preferred component of the therapeutic/skinprotective/skin conditioning compositions useful in the methods of thepresent invention is an agent capable of immobilizing the composition(including the preferred emollient and/or other skinconditioning/therapeutic/protective agents) in the desired location inor on the treated article. Because certain of the preferred emollientsin the composition have a plastic or liquid consistency at 20° C., theytend to flow or migrate, even when subjected to modest shear. Whenapplied to a wearer-contacting surface or other location of an absorbentarticle, especially in a melted or molten state, the emollient will notremain primarily in or on the treated region. Instead, the emollientwill tend to migrate and flow to undesired regions of the article.

Specifically, if the emollient migrates into the interior of thearticle, it can cause undesired effects on the absorbency of the articlecore due to the hydrophobic characteristics of many of the emollientsand other skin conditioning agents used in the compositions useful inthe methods of the present invention. It also means that much moreemollient has to be applied to the article to get the desired skinsmoothness benefits. Increasing the level of emollient not onlyincreases the cost, but also exacerbates the undesirable effect on theabsorbency of the article's core and undesired transfer of compositionduring processing/converting of the treated articles.

The immobilizing agent counteracts this tendency of the emollient tomigrate or flow by keeping the emollient primarily localized on thesurface or in the region of the article to which the composition isapplied. This is believed to be due, in part, to the fact that theimmobilizing agent raises the melting point and/or viscosity of thecomposition above that of the emollient. Since the immobilizing agent ispreferably miscible with the emollient (or solubilized in the emollientwith the aid of an appropriate emulsifier or dispersed therein), itentraps the emollient on the surface of the article's wearer contactingsurface or in the region to which it is applied.

It is also advantageous to “lock” the immobilizing agent on the wearercontacting surface or the region of the article to which it is applied.This can be accomplished by using immobilizing agents which quickly setup (i.e., solidify) upon application to the article. In addition,outside cooling of the treated article via blowers, fans, cold rolls,etc. can speed up crystallization of the immobilizing agent.

In addition to being miscible with (or solubilized in) the emollient,the immobilizing agent will preferably have a melting profile that willprovide a composition that is solid or semisolid at ambient temperature.In this regard, preferred immobilizing agents will have a melting pointof at least about 35° C. This is so the immobilizing agent itself willnot have a tendency to migrate or flow. Preferred immobilizing agentswill have melting points of at least about 40° C. Typically, theimmobilizing agent will have a melting point in the range of from about50_to about 150_C.

When utilized, immobilizing agents useful herein can be selected fromany of a number of agents, so long as the preferred properties of theskin care composition provide the skin benefits described herein.Preferred immobilizing agents will comprise a member selected from thegroup consisting of C₁₄-C₂₂ fatty alcohols, C₁₂-C₂₂ fatty acids, andC₁₂-C₂₂ fatty alcohol ethoxylates having an average degree ofethoxylation ranging from 2 to about 30, and mixtures thereof. Preferredimmobilizing agents include C₁₆-C₁₈ fatty alcohols, most preferablycrystalline high melting materials selected from the group consisting ofcetyl alcohol, stearyl alcohol, behenyl alcohol, and mixtures thereof.(The linear structure of these materials can speed up solidification onthe treated absorbent article.) Mixtures of cetyl alcohol and stearylalcohol are particularly preferred. Other preferred immobilizing agentsinclude C₁₆-C₁₈ fatty acids, most preferably selected from the groupconsisting of palmitic acid, stearic acid, and mixtures thereof.Mixtures of palmitic acid and stearic acid are particularly preferred.Still other preferred immobilizing agents include C₁₆-C₁₈ fatty alcoholethoxylates having an average degree of ethoxylation ranging from about5 to about 20. Preferably, the fatty alcohols, fatty acids and fattyalcohols are linear. Importantly, these preferred immobilizing agentssuch as the C₁₆-C₁₈ fatty alcohols increase the rate of crystallizationof the composition causing the composition to crystallize rapidly ontothe surface of the substrate.

Other types of ingredients that can be used as immobilizing agents,either alone, or in combination with the above-mentioned immobilizingagents, include waxes such as camauba, ozokerite, beeswax, candelilla,paraffin, ceresin, esparto, ouricuri, rezowax, isoparafin, and otherknown mined and mineral waxes. The high melt point of these materialscan help immobilize the composition on the desired surface or locationon the article. Additionally microcrystalline waxes are effectiveimmobilizing agents. Microcrystalline waxes can aid in “locking” up lowmolecular weight hydrocarbons within the skin care composition.Preferably the wax is a paraffin wax. An example of a particularlypreferred alternate immobilizing agent is a paraffin wax such as ParrafmS.P. 434 from Strahl and Pitsch Inc. P.O. Box 1098 West Babylon, N.Y.11704.

Suitable polyhydroxy fatty acid esters for use in the present inventionwill have the formula:

wherein R is a C₅-C₃₁ hydrocarbyl group, preferably straight chainC₇-C₁₉ alkyl or alkenyl, more preferably straight chain C₉-C₁₇ alkyl oralkenyl, most preferably straight chain C₁₁-C₁₇ alkyl or alkenyl, ormixture thereof; Y is a polyhydroxyhydrocarbyl moiety having ahydrocarbyl chain with at least 2 free hydroxyls directly connected tothe chain; and n is at least 1. Suitable Y groups can be derived frompolyols such as glycerol, pentaerythritol; sugars such as raffinose,maltodextrose, galactose, sucrose, glucose, xylose, fructose, maltose,lactose, mannose and erythrose; sugar alcohols such as erythritol,xylitol, malitol, mannitol and sorbitol; and anhydrides of sugaralcohols such as sorbitan.

One class of suitable polyhydroxy fatty acid esters for use in thepresent invention comprises certain sorbitan esters, preferably thesorbitan esters of C₁₆-C₂₂ saturated fatty acids. Because of the mannerin which they are typically manufactured, these sorbitan esters usuallycomprise mixtures of mono-, di-, tri-, etc. esters. Representativeexamples of suitable sorbitan esters include sorbitan palmitates (e.g.,SPAN 40), sorbitan stearates (e.g., SPAN 60), and sorbitan behenates,that comprise one or more of the mono-, di- and tri-ester versions ofthese sorbitan esters, e.g., sorbitan mono-, di- and tri-palmitate,sorbitan mono-, di- and tri-stearate, sorbitan mono-, di andtri-behenate, as well as mixed tallow fatty acid sorbitan mono-, di- andtri-esters. Mixtures of different sorbitan esters can also be used, suchas sorbitan palmitates with sorbitan stearates. Particularly preferredsorbitan esters are the sorbitan stearates, typically as a mixture ofmono-, di- and tri-esters (plus some tetraester) such as SPAN 60, andsorbitan stearates sold under the trade name GLYCOMUL-S by Lonza, Inc.Although these sorbitan esters typically contain mixtures of mono-, di-and tri-esters, plus some tetraester, the mono- and di-esters areusually the predominant species in these mixtures.

Another class of suitable polyhydroxy fatty acid esters for use in thepresent invention comprises certain glyceryl monoesters, preferablyglyceryl monoesters of C₁₆-C₂₂ saturated fatty acids such as glycerylmonostearate, glyceryl monopalmitate, and glyceryl monobehenate. Again,like the sorbitan esters, glyceryl monoester mixtures will typicallycontain some di- and triester. However, such mixtures should containpredominantly the glyceryl monoester species to be useful in the presentinvention.

Another class of suitable polyhydroxy fatty acid esters for use in thepresent invention comprise certain sucrose fatty acid esters, preferablythe C₁₂-C₂₂ saturated fatty acid esters of sucrose. Sucrose monoestersand diesters are particularly preferred and include sucrose mono- anddi-stearate and sucrose mono- and di- laurate.

Suitable polyhydroxy fatty acid amides for use in the present inventionwill have the formula:

wherein R¹ is H, C₁-C₄ hydrocarbyl, 2-hydroxyethyl, 2-hydroxypropyl,methoxyethyl, methoxypropyl or a mixture thereof, preferably C₁-C₄alkyl, methoxyethyl or methoxypropyl, more preferably C₁ or C₂ alkyl ormethoxypropyl , most preferably C₁ alkyl (i.e., methyl) ormethoxypropyl; and R² is a C₅-C₃₁ hydrocarbyl group, preferably straightchain C₇-C₁₉ alkyl or alkenyl, more preferably straight chain C₉-C₁₇alkyl or alkenyl, most preferably straight chain C₁₁-C₁₇ alkyl oralkenyl, or mixture thereof; and Z is a polyhydroxyhydrocarbyl moietyhaving a linear hydrocarbyl chain with at least 3 hydroxyls directlyconnected to the chain. See U.S. Pat. No. 5,174, 927 (Honsa), issuedDec. 29, 1992 (herein incorporated by reference) which discloses thesepolyhydroxy fatty acid amides, as well as their preparation.

The Z moiety preferably will be derived from a reducing sugar in areductive amination reaction; most preferably glycityl. Suitablereducing sugars include glucose, fructose, maltose, lactose, galactose,mannose, and xylose. High dextrose corn syrup, high fructose corn syrup,and high maltose corn syrup can be utilized, as well as the individualsugars listed above. These corn syrups can yield mixtures of sugarcomponents for the Z moiety.

The Z moiety preferably will be selected from the group consisting of—CH₂—(CHOH)_(n)—CH₂OH, —CH(CH₂OH)—[(CHOH)_(n-1)]—CH₂OH,—CH₂OH—CH₂—(CHOH)₂(CHOR³)(CHOH)—CH₂OH, where n is an integer from 3 to5, and R³ is H or a cyclic or aliphatic monosaccharide. Most preferredare the glycityls where n is 4, particularly —CH₂—(CHOH)₄—CH₂OH.

In the above formula, R¹ can be, for example, N-methyl, N-ethyl,N-propyl, N-isopropyl, N-butyl, N-2-hydroxyethyl, N-methoxypropyl orN-2-hydroxypropyl. R² can be selected to provide, for example,cocamides, stearamides, oleamides, lauramides, myristamides,capricamides, palmitamides, tallowamides, etc. The Z moiety can be1-deoxyglucityl, 2-deoxyfructityl, 1-deoxymaltityl, 1-deoxylactityl,1-deoxygalactityl, 1-deoxymannityl, 1-deoxymaltotriotityl, etc.

The most preferred polyhydroxy fatty acid amides have the generalformula:

wherein R¹ is methyl or methoxypropyl; R² is a C₁₁-C₁₇ straight-chainalkyl or alkenyl group. These include N-lauryl-N-methyl glucamide,N-lauryl-N-methoxypropyl glucamide, N-cocoyl-N-methyl glucamide,N-cocoyl-N-methoxypropyl glucamide, N-palmityl-N-methoxypropylglucamide, N-tallowyl-N-methyl glucamide, or N-tallowyl-N-methoxypropylglucamide.

As previously noted, some of the immobilizing agents may require anemulsifier for solubilization in the emollient. This is particularly thecase for certain of the glucamides such as the N-alkyl-N-methoxypropylglucamides having HLB values of at least about 7. Suitable emulsifierswill typically include those having HLB values below about 7. In thisregard, the sorbitan esters previously described, such as the sorbitanstearates, having HLB values of about 4.9 or less have been found usefulin solubilizing these glucamide immobilizing agents in petrolatum. Othersuitable emulsifiers include steareth-2 (polyethylene glycol ethers ofstearyl alcohol that conform to the formula CH₃(CH₂)₁₇(OCH₂CH₂)_(n)OH,where n has an average value of 2), sorbitan tristearate, isosorbidelaurate, and glyceryl monostearate. The emulsifier can be included in anamount sufficient to solubilize the immobilizing agent in the emollientsuch that a substantially homogeneous mixture is obtained. For example,an approximately 1:1 mixture of N-cocoyl-N-methyl glucamide andpetrolatum that will normally not melt into a single phase mixture, willmelt into a single phase mixture upon the addition of 20% of a 1:1mixture of Steareth-2 and sorbitan tristearate as the emulsifier.

Other types of ingredients that can be used as immobilizing agents,either alone, or in combination with the above-mentioned immobilizingagents, include waxes such as carnauba, beeswax, candelilla, paraffm,ceresin, esparto, ouricuri, rezowax, and other known waxes. Preferablythe wax is a paraffin wax. An example of a particularly preferredparaffin wax is Parrafm S.P. 434 from Strahl and Pitsch Inc. P.O. Box1098 West Babylon, N.Y. 11704.

The amount of the optional immobilizing agent that can be included inthe composition will depend on a variety of factors, including theactives (e.g., emollients) involved, the particular immobilizing agentinvolved, the other components in the composition, whether an emulsifieris required to solubilize the immobilizing agent in the othercomponents, and like factors. When present, the composition willtypically comprise from about 5 to about 90% of the immobilizing agent.Preferably, the composition will comprise from about 5 to about 50%,most preferably from about 10 to about 40%, of the immobilizing agent.

Of course, it is highly desirable that at least a portion of thearticle's structured carrier be made of a hydrophilic material topromote rapid transfer of liquids (e.g., urine) through the structuredcarrier. Similarly, it may be desirable that the composition besufficiently wettable to ensure that liquids will transfer through thestructured carrier rapidly. Alternatively, hydrophobic skin carecomposition may be utilized, so long as they are applied such that thefluid handling properties of the structured carrier are adequatelymaintained. (For example, as discussed below, nonuniform application ofthe composition to the structured carrier is one means to accomplishthis goal.) This diminishes the likelihood that body exudates will flowoff the composition-treated structured carrier rather than being drawnthrough the structured carrier and being absorbed by the absorbent core.

Where a hydrophilic composition is desired, depending upon theparticular components used in the composition, a hydrophilic surfactant(or a mixture of hydrophilic surfactants) may, or may not, be requiredto improve wettability. For example, some immobilizing agents, such asN-cocoyl-N-methoxypropyl glucamide have HLB values of at least about 7and are sufficiently wettable without the addition of hydrophilicsurfactant. Other immobilizing agents such as the C₁₆-C₁₈ fatty alcoholshaving HLB values below about 7 may require addition of hydrophilicsurfactant to improve wettability when the composition is applied toarticle structured carriers. Similarly, a hydrophobic emollient such aspetrolatum may require the addition of a hydrophilic surfactant ifhydrophilic composition is desired. Of course, the concern aroundwettability is not a factor when the wearer-contacting surface underconsideration is other than the article's structured carrier or whenfluid handling properties of the structured carrier are adequatelymaintained via other means (e.g., nonuniform application).

Suitable hydrophilic surfactants will preferably be miscible with theother components of the skin care composition so as to form blendedmixtures. Because of possible skin sensitivity of those using disposableabsorbent products to which the composition is applied, thesesurfactants should also be relatively mild and non-irritating to theskin. Typically, these hydrophilic surfactants are nonionic to be notonly non-irritating to the skin, but also to avoid other undesirableeffects on any other structures within the treated article. For example,reductions in tissue laminate tensile strength, adhesive bondsufficiencies, and the like.

Suitable nonionic surfactants may be substantially nonmigratory afterthe composition is applied to the article and will typically have HLBvalues in the range of from about 4 to about 20, preferably from about 7to about 20. To be nonmigratory, these nonionic surfactants willtypically have melt temperatures greater than the temperatures commonlyencountered during storage, shipping, merchandising, and use ofdisposable absorbent products, e.g., at least about 30° C. In thisregard, these nonionic surfactants will preferably have melting pointssimilar to those of the immobilizing agents previously described.

Suitable nonionic surfactants for use in compositions that will beapplied to the articles, at least in the liquid discharge region of thediaper, include alkylglycosides; alkylglycoside ethers as described inU.S. Pat. No. 4,011,389 (Langdon, et al), issued Mar. 8, 1977, which isincorporated by reference; alkylpolyethoxylated esters such asPegosperse 1OOOMS (available from Lonza, Inc., Fair Lawn, N.J.),ethoxylated sorbitan mono-, di- and/or tri-esters of C₁₂-C₁₈ fatty acidshaving an average degree of ethoxylation of from about 2 to about 20,preferably from about 2 to about 10, such as TWEEN 60 (sorbitan estersof stearic acid having an average degree of ethoxylation of about 20)and TWEEN 61 (sorbitan esters of stearic acid having an average degreeof ethoxylation of about 4), and the condensation products of aliphaticalcohols with from about 1 to about 54 moles of ethylene oxide. Thealkyl chain of the aliphatic alcohol is typically in a straight chain(linear) configuration and contains from about 8 to about 22 carbonatoms. Particularly preferred are the condensation products of alcoholshaving an alkyl group containing from about 11 to about 22 carbon atomswith from about 2 to about 30 moles of ethylene oxide per mole ofalcohol. Examples of such ethoxylated alcohols include the condensationproducts of myristyl alcohol with 7 moles of ethylene oxide per mole ofalcohol, the condensation products of coconut alcohol (a mixture offatty alcohols having alkyl chains varying in length from 10 to 14carbon atoms) with about 6 moles of ethylene oxide. A number of suitableethoxylated alcohols are commercially available, including TERGITOL15-S-9 (the condensation product of C₁₁-C₁₅ linear alcohols with 9 molesof ethylene oxide), marketed by Union Carbide Corporation; KYRO EOB(condensation product of C₁₃-C₁₅ linear alcohols with 9 moles ofethylene oxide), marketed by The Procter & Gamble Co., the NEODOL brandname surfactants marketed by Shell Chemical Co., in particular NEODOL25-12 (condensation product of C₁₂-C₁₅ linear alcohols with 12 moles ofethylene oxide) and NEODOL 23-6.5T (condensation product of C₁₂-C₁₃linear alcohols with 6.5 moles of ethylene oxide that has been distilled(topped) to remove certain impurities), and especially the PLURAFACbrand name surfactants marketed by BASF Corp., in particular PLURAFACA-38 (a condensation product of a C₁₈ straight chain alcohol with 27moles of ethylene oxide). (Certain of the hydrophilic surfactants, inparticular ethoxylated alcohols such as NEODOL 25-12, can also functionas alkyl ethoxylate emollients). Other examples of preferred ethoxylatedalcohol surfactants include ICI's class of Brij surfactants and mixturesthereof, with Brij 72 (i.e., Steareth-2) and Brij 76 (i.e., Steareth-10)being especially preferred. Also, mixtures of cetyl alcohol and stearylalcohol ethoxylated to an average degree of ethoxylation of from about10 to about 20 may also be used as the hydrophilic surfactant.

Another type of suitable surfactant for use in the composition includesAerosol OT, a dioctyl ester of sodium sulfosuccinic acid marketed byAmerican Cyanamid Company.

Still another type of suitable surfactant for use in the compositionincludes silicone copolymers such as General Electric SF 1188 (acopolymer of a polydimethylsiloxane and a polyoxyalkylene ether) andGeneral Electric SF 1228 (a silicone polyether copolymer). Thesesilicone surfactants can be used in combination with the other types ofhydrophilic surfactants discussed above, such as the ethoxylatedalcohols. These silicone surfactants have been found to be effective atconcentrations as low as 0.1%, more preferably from about 0.25 to about1.0%, by weight of the composition.

The amount of hydrophilic surfactant required to increase thewettability of the composition to a desired level will depend in-partupon the HLB value and level of immobilizing agent, if any, used, theHLB value of the surfactant used and like factors. The composition cancomprise from about 0.1 to about 50% of the hydrophilic surfactant whenneeded to increase the wettability properties of the composition.Preferably, the composition comprises from about 1 to about 25%, mostpreferably from about 10 to about 20%, of the hydrophilic surfactantwhen needed to increase wettability.

Compositions can comprise other components typically present inemulsions, creams, ointment, lotions, powders, suspensions, etc. of thistype. These components include water, viscosity modifiers, perfumes,disinfectant antibacterial actives, antiviral agents, vitamins,pharmaceutical actives, film formers, deodorants, opacifiers,astringents, solvents, preservatives, and the like. In addition,stabilizers can be added to enhance the shelf life of the compositionsuch as cellulose derivatives, proteins and lecithin. All of thesematerials are well known in the art as additives for such formulationsand can be employed in appropriate amounts in the compositions for useherein.

If water-based skin care compositions are used, a preservative will beneeded. Suitable preservatives include propyl paraben, methyl paraben,benzyl alcohol, benzylkonnium, tribasic calcium phosphate, BHT, or acidssuch as citric, tartaric, maleic, lactic, malic, benzoic, salicylic, andthe like. Suitable viscosity increasing agents include some of theagents described as effective immobilizing agents. Other suitableviscosity increasing agents include alkyl galactomannan, silica, talc,magnesium silicate, sorbitol, colloidal silicone dioxide, magnesiumaluminum silicate, zinc stearate, wool wax alcohol, sorbiton,sesquioleate, cetyl hydroxy ethyl cellulose and other modifiedcelluloses. Suitable solvents include propylene glycol, glycerine,cyclomethicone, polyethylene glycols, hexalene glycol, diol andmulti-hydroxy based solvents. Suitable vitamins include A, D3, E, B5 andE acetate.

In preparing products according to the present invention, the lotioncomposition is applied to the outer surface (i.e., body facing surface)of an article structured carrier. Any of a variety of applicationmethods that distribute lubricious materials having a molten or liquidconsistency can be used. Suitable methods include spraying, printing(e.g., flexographic printing), coating (e.g., gravure coating),extrusion, or combinations of these application techniques, e.g.spraying the composition on a rotating surface, such as a calender roll,that then transfers the composition to the outer surface of the articlestructured carrier.

Because the structured carrier has an effective open area and aplurality of apertures having a sufficient effective size, urine andlow-viscosity fecal material can penetrate the structured carrierregardless of the amount of skin care composition which has been appliedto the structured carrier. Accordingly, even if the structured carrieris completely saturated with skin care composition urine andlow-viscosity fecal material will readily penetrate therethrough becausethe very structure of the carrier creates sufficient separation betweenregions of the applied skin care composition, allowing fluids topenetrate the carrier unobstructed. The problem of occlusion has beensolved by providing a structured carrier having an effective open areaand a plurality of apertures having a sufficient effective size.

An effective amount of composition needs to be applied to the structuredcarrier for reducing the adherence of BM to the skin and/or providing askin benefit to the wearer. The composition is preferably applied to thearticle structured carrier in an amount ranging from about 0.1 mg/in² toabout 35 mg/in². Such levels of composition are believed to be adequateto impart the desired therapeutic and/or protective benefits to thestructured carrier.

Since the problem of occlusion has been solved, the composition may beapplied to the outer surface of the structured carrier in any mannerdesired. For example, the composition may be applied to the entire outersurface or only portions thereof. The composition can also be appliednonuniformly to the outer surface of the structured carrier. By“nonuniform” it is meant that the amount, location, pattern ofdistribution, etc. of the composition can vary over the structuredcarrier surface. For example, some portions of the treated surface ofthe structured carrier can have greater or lesser amounts ofcomposition, including portions of the surface that do not have anycomposition on it.

The composition can be applied to the structured carrier at any pointduring assembly. For example, the composition can be applied to thestructured carrier of the finished disposable absorbent product beforeit has been packaged. The composition can also be applied to thestructured carrier before it is combined with the other raw materials toform a finished disposable absorbent product.

The composition is typically applied from a melt thereof to the articlestructured carrier. Since the composition melts at significantly aboveambient temperatures, it is usually applied as a heated coating to thestructured carrier. Typically, the composition is heated to atemperature in the range from about 35_to about 100_C, preferably from40_ to about 90_C, prior to being applied to the article structuredcarrier. Once the melted composition has been applied to the articlestructured carrier, it is allowed to cool and solidify to formsolidified coating or film on the surface of the structured carrier.Preferably, the application process is designed to aid in thecooling/set up of the composition.

The diaper 20 may further comprise elasticized leg cuffs (not shown)which provide improved containment of liquids and other body exudates.Each elasticized leg cuff may comprise several different embodiments forreducing the leakage of body exudates in the leg regions. (The leg cuffcan be and is sometimes also referred to as leg bands, side flaps,barrier cuffs, or elastic cuffs.) U.S. Pat. No. 3,860,003 describes adisposable diaper 20 which provides a contractible leg opening having aside flap and one or more elastic members to provide an elasticized legcuff (gasketing cuff). Commonly assigned U.S. Pat. No. 4,909,803entitled “Disposable Absorbent Article Having Elasticized Flaps” issuedto Aziz et al. on Mar. 20, 1990, describes a disposable diaper 20 having“stand-up” elasticized flaps (barrier cuffs) to improve the containmentof the leg regions. Commonly assigned U.S. Pat. No. 4,695,278 entitled“Absorbent Article Having Dual Cuffs” issued to Lawson on Sep. 22, 1987,describes a disposable diaper 20 having dual cuffs including a gasketingcuff and a barrier cuff.

The diaper 20 preferably further comprises an elastic waist feature (notshown) that provides improved fit and containment. The elastic waistfeature is that portion or zone of the diaper 20 which is intended toelastically expand and contract to dynamically fit the wearer's waist.The elastic waist feature at least extends longitudinally outwardly fromat least one of the waist edges of the absorbent core 28 and generallyforms at least a portion of the end edge of the diaper 20. Disposablediapers are generally constructed so as to have two elastic waistfeatures, one positioned in the first waist region 27 and one positionedin the second waist region 29, although diapers can be constructed witha single elastic waist feature. Further, while the elastic waist featureor any of its constituent elements can comprise a separate elementaffixed to the diaper 20, the elastic waist feature is preferablyconstructed as an extension of other elements of the diaper 20 such asthe backsheet 26 or the structured carrier 24, preferably both thebacksheet 26 and the structured carrier 24. The elasticized waistband 34may be constructed in a number of different configurations includingthose described in U.S. Pat. No. 4,515,595 issued to Kievit et al. onMay 7, 1985 and the above referenced U.S. patent application Ser. No.07/715,152; each of these references being incorporated herein byreference.

The diaper 20 also comprises a fastening system 36 which forms a sideclosure which maintains the first waist region 27 and the second waistregion 29 in an overlapping configuration such that lateral tensions aremaintained around the circumference of the diaper 20 to maintain thediaper 20 on the wearer. Exemplary fastening systems are disclosed inU.S. Pat. No. 4,846,815 entitled “Disposable Diaper Having An ImprovedFastening Device” issued to Scripps on Jul. 11, 1989; U.S. Pat. No.4,894,060 entitled “Disposable Diaper With Improved Hook FastenerPortion” issued to Nestegard on Jan. 16, 1990; commonly assigned U.S.Pat. No. 4,946,527 entitled “Pressure-Sensitive Adhesive Fastener AndMethod of Making Same” issued to Battrell on Aug. 7, 1990; commonlyassigned U.S. Pat. No. 3,848,594 entitled “Tape Fastening System forDisposable Diaper” issued to Buell on Nov. 19, 1974; commonly assignedU.S. Pat. No. B1 4,662,875 entitled “Absorbent Article” issued toHirotsu et al. on May 5, 1987; and the hereinbefore referenced U.S.patent application Ser. No. 07/715,152; each of which is incorporatedherein by reference.

The diaper 20 is preferably applied to a wearer by positioning one ofthe waist regions, preferably the second waist region 29, under thewearer's back and drawing the remainder of the diaper 20 between thewearer's legs so that the other waist region, preferably the first waistregion 27, is positioned across the front of the wearer. The tape tabs36 of the fastening system are then released from the release portion.The diaperer then wraps the elasticized side panel around the wearer,while still grasping the tab portion. The fastening system is secured tothe outer surface of the diaper 20 to effect two side closure.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A disposable absorbent article comprising: aliquid pervious structured carrier having an inner surface orientedtoward the interior of said disposable absorbent article and an outersurface oriented toward the skin of the wearer when the disposableabsorbent article is worn, said structured carrier having an effectiveopen area of at least about 12 percent and a plurality of apertures withan effective size greater than 0.1 square millimeters, said outersurface of said structured carrier comprising an effective amount of askin care composition which is semi-solid or solid at 20° C. and whichis partially transferable to the wearer's skin; a liquid imperviousbacksheet at least partially peripherally joined to said structuredcarrier; and an absorbent core intermediate said structured carrier andsaid backsheet.
 2. The disposable absorbent article according to claim 1wherein said structured carrier has an effective open area of at leastabout 15 percent.
 3. The disposable absorbent article according to claim1 wherein said structured carrier has an effective open area of at leastabout 20 percent.
 4. The disposable absorbent article according to claim1 wherein said structured carrier has an effective open area of at leastabout 30 percent.
 5. The disposable absorbent article according to claim1 wherein said structured carrier has a plurality of apertures with asize greater than 0.2 square millimeters.
 6. The disposable absorbentarticle according to claim 1 wherein said structured carrier has aplurality of apertures with a size greater than 0.5 square millimeters.7. The disposable absorbent article according to claim 1 wherein saidstructured carrier has a plurality of apertures with a size greater than1.0 square millimeters.
 8. The disposable absorbent article according toclaim 1 wherein said structured carrier has a plurality of apertureswith a size greater than 2.0 square millimeters.
 9. The disposableabsorbent article of claim 1 wherein the skin care composition comprisesa petroleum based emollient selected from the group consisting ofmineral oil, petrolatum, and mixtures thereof.
 10. The disposableabsorbent article of claim 1 wherein said skin care compositioncomprises an immobilizing agent, said immobilizing agent having amelting point of at least about 40° C.
 11. The disposable absorbentarticle of claim 10 wherein said immobilizing agent is selected from thegroup consisting of polyhydroxy fatty esters, polyhydroxy fatty acidamides, C₁₄-C₂₂ fatty alcohols, C₁₂-C₂₂ fatty acids, C₁₂-C₂₂ fattyalcohol ethoxylates, and mixtures thereof.
 12. The disposable absorbentarticle of claim 11 wherein said immobilizing agent comprises a C₁₆-C₁₈fatty alcohol selected from the group consisting of cetyl alcohol,stearyl alcohol, and mixtures thereof.
 13. The disposable absorbentarticle of claim 9 wherein said immobilizing agent comprises apolyhydroxy fatty acid ester having the formula:

wherein R is a C₅-C₃₁ hydrocarbyl group; Y is a polyhydroxyhydrocarbylmoiety having a hydrocarbyl chain with at least 2 free hydroxylsdirectly connected to the chain; and n is at least
 1. 14. The disposableabsorbent article of claim 9 wherein said immobilizing agent comprises apolyhydroxy fatty acid amide having the formula:

wherein R¹ is H, C₁-C₄ hydrocarbyl, 2-hydroxyethyl, 2-hydroxypropyl,methoxyethyl, methoxypropyl or a mixture thereof; R² is a C₅-C₃₁hydrocarbyl group; and Z is a polyhydroxyhydrocarbyl moiety having alinear hydrocarbyl chain with at least 3 hydroxyls directly connected tothe chain.
 15. The disposable absorbent article of claim 9 wherein saidimmobilizing agent comprises a paraffin wax.
 16. The disposableabsorbent article of claim 1 wherein said skin care compositioncomprises a polysiloxane emollient having a plastic or fluid consistencyat 20° C.
 17. The disposable absorbent article of claim 1 wherein saidstructured carrier has an effective open area of at least about 20percent and a plurality of apertures with a size greater than 0.2 squaremillimeters.
 18. The disposable absorbent article of claim 1 whereinsaid structured carrier has an effective open area of at least about 30percent and a plurality of apertures with a size greater than 2.0 squaremillimeters.
 19. The disposable absorbent article of claim 1 whereinsaid skin care composition comprises a polyol polyester emollient.